SERVICE BULLETIN
Release Date: July 29, 2021

LEV

Expiration Date: July 29, 2023

Communication #: L-21-01
Model Year(s): 2016-2021

— Confidential and Proprietary —

VERSION: R01 (July 29, 2021)
IMPORTANT
If you are working with a printed copy, please verify you have the most current version of this document.

SUBJECT: FAST CHARGER WIRE HARNESS
PURPOSE
Some 2016-2021 GEM vehicles built with Fast Chargers (3 kW or 6 kW) may experience a premature failure to the charger
itself, if a short circuit occurs on the vehicle.
To address this concern, GEM is releasing this Service Bulletin for dealers to replace the fast charger harness in all affected
vehicles with a new harness that has a built-in fuse holder. Please refer to the instructions within this Bulletin.
IMPORTANT
If a vehicle was upgraded to a Fast Charger option in the field, and is not showing as affected by this Bulletin, please
contact Technical Service to have the vehicle added to this Bulletin.

AFFECTED MODELS
MODEL YEAR

MODELS

AFFECTED RANGE

e2

Reference Unit Inquiry on the dealer website or
the Service Communications list on the STOP
site to look up affected units.

e4
2016-2021

e6
**This Bulletin only applies to vehicles with
either the 3 kW or 6 kW Fast Charger option
installed.**

eL XD

CUSTOMER NOTIFICATION
Dealers are required to review their sales records and make arrangements with customers for Bulletin completion. In
addition to consumer units, dealers are required to correct any affected units in their inventory. Polaris will NOT be mailing a
notification letter to consumers affected by this Bulletin.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the written
consent of Polaris Inc.
L-21-01 (R01)

© 2021 Polaris Inc.

Page 1 of 7

WARRANTY CLAIM INFORMATION
Bulletin parts are excluded from the standard RMA policy and cannot be returned. An Initial Recommended Order Quantity
has not been provided for this bulletin. Use Quantity Ordered to Date and the Open VIN / PIN List from the STOP site to
determine an order amount that’s right for your dealership. For more details, refer to University of Polaris training course
"Polaris Item Availability and Daily Ordering" and click on "Bulletin Ordering Training".
2016-2021 GEM E2, E4, E6, EL XD
BUILT WITH FAST CHARGER (3 KW OR 6 KW)
Bulletin #

L-21-01

Claim Type

SB (Service Bulletin)

Labor Allowance

0.8 hours (48 minutes)

Part Number / Description

2416229 (QTY 1) HARNESS-CHARGER,FAST,MAIN,FSD
7080492 (QTY 7) CABLE TIE, 11 IN

Parts Availability

Available to order

University of Polaris Video Training
Required

NO

Claim Submission:
• US / Canada Dealers: On DEX, go to Service and Warranty > Warranty Claim and Extended Coverage > Start a New
Warranty Claim. Select Service Bulletin > Enter the VIN / PIN and Retrieve Registration. Select L-21-01 and Send Claim.
• International Dealers: On iDEX, go to Service and Warranty> Warranty Claims>Start a New Warranty Claim. Select
Service Bulletin > Enter the VIN / PIN and Retrieve Registration. Select L-21-01 and Send Claim

INVENTORY / STOCK PART CLAIMS
Dealers should review their service parts inventory and ensure the following service parts are NOT used:
• 2414683
• 2413708
NOTICE
To remove these service parts from circulation, file a Part Stock claim as directed below.
Use the following process for filing a Part Stock warranty claim for any of the parts listed above.
1. Start a new Part Stock warranty claim.
2. Select Product Line: LEV
3. Enter today’s date into the Date Failed and Date Repair information fields
4. Enter L-21-01 into the CONCERN field.
5. Enter L-21-01 into the CAUSE field.
6. Enter Removed From Inventory into the CORRECTION field.
7. Enter the part number and quantity.
8. Enter warranty fail codes: 142/279/209
9. Validate the parts.
10. Save and submit the claim to Polaris.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the written
consent of Polaris Inc.
L-21-01 (R01)

© 2021 Polaris Inc.

Page 2 of 7

ACCESSORY LABOR
Polaris will cover labor for the removal and installation of accessories required to complete the bulletin work. Follow the
steps below to obtain reimbursement.
For accessory removal and installation up to 30 minutes of labor:
Enter the actual labor time for the removal and installation into the Accessory R&R Min Field on the bulletin claim.
For accessory removal and installation over 30 minutes of labor:
1. Start a new Ask Polaris Case, Service &Warranty Question > Authorization: In Warranty or Polaris ESC or Authorization:
Out of Warranty.
2. Enter your contact information and VIN / PIN, along with miles and hours into the applicable fields.
3. Enter L-21-01 in the CONCERN and CAUSE fields. In the CORRECTION field, enter "ACCESSORY REMOVAL AND
INSTALLATION".
4. Enter warranty fail codes 142/279/209.
5. Add part 0000541, quantity 1.
6. Attach photos of the vehicle and accessories sufficient to support the labor time requested.
7. Submit the case to Polaris.

BULLETIN CONTACT LIST & SCHEDULING TOOL
A scheduling tool is available for dealers to keep a record of customers contacted and scheduled for this bulletin. This
optional tool provides visibility for your dealership and will be helpful to track the status of scheduled service. For more
information, log in to http://www.universityofpolaris.com.

COVERAGE PERIOD
Coverage will begin on July 29, 2021. Coverage will expire on July 29, 2023.

PARTS RETURN / DISPOSAL INFORMATION
Under no circumstances shall the parts removed be re-used, sold, or re-purposed for another application. It is your
dealership / distributor’s responsibility to make sure every part replaced (related to this communication) is taken out of
circulation and disposed of properly or returned to Polaris (if required).

FEEDBACK FORM
A feedback form has been created for the technician to provide Polaris with an overall
satisfaction rating for the instructions, provide comments on your experience or upload
pictures/video. The form is viewable on mobile devices by scanning the QR code or on a
PC by clicking HERE.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the written
consent of Polaris Inc.
L-21-01 (R01)

© 2021 Polaris Inc.

Page 3 of 7

L-21-01 PROCEDURE
TOOLS REQUIRED

5. Unplug the vehicle from charging, then disconnect
power at the service disconnect located near the front
left wheel of the vehicle.

• Multi-Function Pliers
• Side Cutters
• 8 mm, 10 mm, 13 mm socket/ratchet
• Torque Wrench

VEHICLE PREPARATION
1. Park the vehicle on a flat, level surface and turn the key
switch to the OFF position.
2. Remove the two hood screws located under the charge
port.

CAUTION
Failure to disconnect the service disconnect plug may
result in electrical short damage to the vehicle electrical
systems.
6. Disconnect the 16–pin connector from the charger
connections.

3. Keeping the hood parallel with the ground, pull the hood
forward to release it from the grommets. Carefully lift the
hood away from the vehicle.

NOTICE
Vehicle shown is equipped with a 6 kW fast charger setup.

4. Plug in the vehicle to charge, and note any fault
conditions.

7. Some vehicles equipped with lithium-ion batteries will
have the auxiliary battery in the rear. For these vehicles:
Remove the 50-amp inline fuse on the red wire to
disconnect power from the auxiliary battery.
WARNING
Improperly or not disconnecting the battery cables can
result in an electric shock when working on electrical
components.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the written
consent of Polaris Inc.
L-21-01 (R01)

© 2021 Polaris Inc.

Page 4 of 7

8. Vehicles with the auxiliary battery under the dash:
Remove six push darts d from upper dash and two in
the glovebox. Retain push darts.

REMOVAL
1. Cut all cable ties that secure the fast charger harness to
the vehicle.
IMPORTANT
Make note of where the cable ties were located, for
installation of the NEW harness.
2. Disconnect the diagnostic connectors q and w, and
disconnect the charge port connector e.
IMPORTANT
Be sure to make note of where the diagnostic connectors
q and w are plugged in for reinstallation, particularly on
vehicles with CAN-based accessories (EPS, speedkey,
etc.).

9. Lift upper dash to access and disconnect electrical
connectors. Remove dash from vehicle.

3. Disconnect the standard charger connector r, and
remove the fast charger harness from the vehicle.
Discard the harness.

10. Disconnect positive (+) battery cable s from the
auxiliary battery under the dash.

WARNING
Improperly or not disconnecting the battery cables can
result in an electric shock when working on electrical
components.
The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the written
consent of Polaris Inc.
L-21-01 (R01)

© 2021 Polaris Inc.

Page 5 of 7

INSTALLATION
1. Install the NEW Fast Charger harness by connecting
the diagnostic connectors t and y, the charge port
connector u, the standard connector o, and the 16–pin
connectors a.

3. Reconnect the positive (+) battery cable s from the
auxiliary battery under the dash.

IMPORTANT
Be sure to install the diagnostic connectors in the
previously-noted locations to ensure any CAN-based
accessories are hooked up properly. For more details,
refer to the "Accessories - CAN-based" section of the
service manual, located in the Electrical chapter.
NOTE
For vehicles equipped with the 3 kW fast charger, the 16pin connector on the left-hand side of vehicle will not be
connected, but can be retained with a cable tie on the
previously noted location.

TORQUE
Auxiliary Battery Terminals:
60 in-lbs (7 N·m)
4. Connect the electrical connectors under the upper dash.

2. Secure the harness with the new cable ties in the
previously notes locations. Retain the new inline fuse
holder i by looping a cable tie through its mounting
hole and securing it to the fast charger harness, itself.
5. Install the six push darts d on the upper dash and the
two in the glovebox.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the written
consent of Polaris Inc.
L-21-01 (R01)

© 2021 Polaris Inc.

Page 6 of 7

6. Connect power at the service disconnect.

7. Verification:
• Test drive the vehicle.
• Plug in the vehicle to verify the charger is operating
correctly.
• If the charger does not power on, verify each connection
is correct and secure, then test the in-line fuse on the
new harness.
• If the charger is still not functioning properly, contact
Technical Service for assistance.
8. Reinstall the hood and two hood screws.
9. Submit a Service Bulletin Warranty Claim for L-21-01.

The information contained within this document is confidential and protected by U.S. and international copyright laws, and is the property of Polaris Inc. This document is
provided for the sole use of authorized Polaris dealers and distributors. This document is not to be distributed, duplicated, or copied, digitally or otherwise, without the written
consent of Polaris Inc.
L-21-01 (R01)

© 2021 Polaris Inc.

Page 7 of 7